Slipping Coupling Drive Position Tracking Without Multiple Markers
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Solution Overview
Problem
Existing electric drive systems in applications like high-bay warehouses and conveyor belts require numerous position markers to compensate for slippage, leading to high installation and maintenance efforts without ensuring safety-related evaluation, especially when single encoders are not safety-rated.
Innovation Solution
An electric drive system with a motor encoder and a load sensor, where the electronic control device calculates the load device's position based on the motor encoder's rotational angle position, compensates for slip by setting the motor encoder position to the load sensor position if slip is below a threshold, and assumes an error state if slip exceeds the threshold, eliminating the need for physical position markers and reducing diagnostic marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If numerous position markers are installed along the path to compensate for slippage, then measurement precision is improved, but device complexity and installation effort increase significantly
Solution Approach 1:
The patent extracts the slippage compensation function from the physical position markers and relocates it to the electronic control device through calculation. Instead of using numerous physical markers along the path, the system uses a single reference position marker combined with motor encoder data to mathematically determine the load device position, thereby eliminating the need for multiple physical markers while maintaining measurement precision
Solution Approach 2:
The patent replaces the mechanical system of multiple physical position markers with an electronic calculation system. The electronic control device computes the load device position based on motor encoder rotational angle data and a single reference position marker, substituting the mechanical marker-based measurement system with an electronic computation approach that achieves the same precision without the complexity of numerous physical markers
2Reliability
If two independent encoders are used for safety evaluation, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple encoders into a single motor encoder system. By combining the motor encoder with electronic calculation of load position based on a single reference marker, the system achieves the safety evaluation functionality of multiple independent encoders while reducing the physical number of encoder devices and simplifying the overall system architecture
Solution Approach 2:
The patent introduces an intermediary calculation system in the electronic control device that mediates between the motor encoder and the load device position determination. This intermediary computation layer processes motor encoder data and reference position marker information to generate accurate load position data, enabling safety evaluation without requiring multiple physical encoders on the load device
3Measurement precision
If many position markers are parameterized and validated during commissioning, then measurement precision is improved, but loss of time during commissioning increases
Solution Approach 1:
The patent extracts the position measurement function from multiple distributed markers and concentrates it in a single reference position marker combined with electronic calculation. This extraction eliminates the need to parameterize and validate numerous markers during commissioning, reducing commissioning time while maintaining the ability to achieve high measurement precision through the calculation system
Data Source
Figure 1~2
AI summary
The invention relates to an electric drive system comprising a motor, a load device and a coupling unit; by comparing signals between a motor sensor and a load sensor, slip is calculated and a motor sensor-based position of the load device is cyclically updated if the slip remains below a slip threshold value.